Atomizer monitoring system

Abstract

An atomizer monitoring system monitors parts or components that are utilized in atomizers for flue gas desulfurization or in spray drying applications, taking into account each part's longevity, installation date, and expiration period, using wireless sensors and radio frequency identification (“RFID”) technology, whereby small, inexpensive RFID tags are placed on, or embedded in the atomizers, for example, in an atomizer wheel. The monitor system can avoid failure of parts within an atomizer and costly downtime associated with removal and replacement of parts that have reached their useful life. The preferred embodiment utilizes radio frequency identification (“RFID”) technology which is linked to a web-based data base.

1. A monitoring system for collecting data relating to wear components of an atomizer for determining when the wear components are in need of replacement, comprising:
 an atomizer including an atomizer wheel, a motor and gear box, and feed components, at least one of the atomizer wheel, motor and gear box including the wear components, the wear components being concealed from visual inspection during operation of the atomizer with each wear component having a remaining service time; 
 a RFID tag attached to said atomizer, said RFID tag storing data associated with the wear components used in said atomizer; 
 a RFID reader in communication with said RFID tag for retrieving the stored data associated with the wear components used in said atomizer; 
 a sensor adjacent said atomizer that monitors when said atomizer is in use; 
 a computer in communication with said sensor for recording a period of time when said atomizer is in use, adjusting the remaining service time for each of the wear components, and indicating when service for said atomizer is required based on one of the adjusted remaining service times. 
 
     
     
       2. The monitoring system of  claim 1 , wherein said RFID tag is embedded in said atomizer wheel and stores data associated with the wear components used in said atomizer wheel. 
     
     
       3. The monitoring system of  claim 2 , wherein said atomizer wheel includes a lid, said RFID tag is a first RFID tag embedded in said lid, and further comprising a second RFID tag embedded in said lid opposite said first RFID tag to counterbalance said first RFID tag, said second RFID tag also storing data associated with the wear components used in said atomizer. 
     
     
       4. The monitoring system of  claim 3 , further comprising a third RFID tag located adjacent said motor and storing data associated with the wear components used in said motor. 
     
     
       5. The monitoring system of  claim 1 , further comprising a mobile PC embedding said RFID reader, said mobile PC in communication with said computer to forward the stored data associated with the wear components used in said atomizer and an identification of said atomizer to said computer. 
     
     
       6. The monitoring system of  claim 1 , wherein said computer displays the service time life expectancy, an expired service time and the expected remaining service time for the wear components to indicate when service for said atomizer is required. 
     
     
       7. A monitoring system for collecting data, comprising:
 a treatment chamber located in a caustic environment having a plurality of wear components, the wear components having different lengths of wear life and being concealed from visual inspection during operation of the treatment chamber with each wear component having a remaining service time; 
 a RFID tag attached to said treatment chamber, said RFID tag identifying said treatment chamber and storing data associated with the wear components used in said treatment chamber; 
 a RFID reader in communication with said RFID tag for retrieving the stored data associated with the wear components used in said treatment chamber; 
 a sensor adjacent said treatment chamber that monitors when said treatment chamber is in use; 
 a computer in communication with said sensor for recording a period of time when said treatment chamber is in use, adjusting the remaining service time for each of the wear components, and indicating when service for said treatment chamber is required based on one of the adjusted remaining service times. 
 
     
     
       8. The monitoring system of  claim 7 , wherein said RFID tag is embedded in one of the wear components of said treatment chamber and stores data associated with the wear components used in said treatment chamber. 
     
     
       9. The monitoring system of  claim 8 , wherein said treatment chamber includes an atomizer wheel having a lid, said RFID tag is a first RFID tag embedded in said lid, and further comprising a second RFID tag embedded in said lid opposite said first RFID tag to counterbalance said first RFID tag, said second RFID tag also storing data associated with the wear components used in said treatment chamber. 
     
     
       10. The monitoring system of  claim 9 , further comprising a third RFID tag located adjacent said treatment chamber and storing data associated with the wear components used in said treatment chamber. 
     
     
       11. The monitoring system of  claim 7 , further comprising a mobile PC embedding said RFID reader, said mobile PC in communication with said computer to forward the stored data associated with the wear components and an identification of said treatment chamber to said computer. 
     
     
       12. The monitoring system of  claim 7 , wherein said computer displays the service time life expectancy, the expired service time and the expected remaining service time for the wear components to indicate when service of said wear components is required. 
     
     
       13. A method for determining when wear components of an atomizer are in need of replacement, comprising:
 (a) attaching a RFID tag to an atomizer having wear components therein operating in a caustic environment, each of the wear components being concealed from visual inspection during operation of the atomizer and having a remaining service time; 
 (b) storing data in the RFID tag associated with the wear components of the atomizer; 
 (c) determining when the atomizer is in use; 
 (d) retrieving the stored data associated with the wear components from the RFID tag attached to the atomizer; 
 (e) adjusting the remaining service time for each of the wear components based on an amount of time the atomizer is in use; and 
 (f) indicating when service for said atomizer is required based on one of the remaining service times. 
 
     
     
       14. The method of  claim 13 , further comprising recording the period of time when the atomizer is in use. 
     
     
       15. The method of  claim 13 , further comprising updating the stored data based on information associated with the atomizer. 
     
     
       16. The method of  claim 13 , wherein step (f) includes displaying the service time life expectancy, an expired service time and the expected remaining service time of the wear components to indicate when service for said atomizer is required. 
     
     
       17. The method of  claim 13 , wherein step (a) includes embedding the RFID tag in an atomizer wheel of the atomizer, and step (b) includes storing data in the RFID tag associated with the wear components used in the atomizer wheel. 
     
     
       18. The method of  claim 17 , wherein the RFID tag is a first RFID tag embedded in the atomizer wheel, and further comprising embedding a second RFID tag in the atomizer wheel opposite the first RFID tag to counterbalance the first RFID tag, and storing data in the second RFID tag associated with the wear components used in the atomizer wheel. 
     
     
       19. The method of  claim 18 , further comprising embedding a third RFID tag adjacent a motor of the atomizer, and storing data in the third RFID tag associated with the wear components used in the motor.